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  #1  
Old 07-30-2014, 12:17 PM
TheDon's Avatar
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W123 Manual shifter rebuild tips and tricks

I replaced the three plastic bushings in my shifter as well as cleaned it up and used fresh grease but one of the round spring washers was fighting me on the reinstall.

Anyone have any tips or tricks on getting it all together? Searching for the rebuild topic brings up nothing on this subject.

I was thinking of using a socket to hold the washers in place with the trapezoid washer not in place and then slide that in to tighten it up and then remove the socket.
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  #2  
Old 07-30-2014, 02:56 PM
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85 300D 4spd+tow+h4
 
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Maybe check 190rev, there are threads there. Should be same/similar design.
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  #3  
Old 07-30-2014, 04:29 PM
t walgamuth's Avatar
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Did you change the plastic top hat thingie? I've done it before but its been 20 years...not that hard I don't think.
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  #4  
Old 07-30-2014, 04:43 PM
winmutt's Avatar
85 300D 4spd+tow+h4
 
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There is a thread on 190rev about custom made delrin hats as replacements for the plastic ones. Might be worth looking into.
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1987 300D Sturmmachine
1991 300D Nearly Perfect
1994 E320 Cabriolet
1995 E320 Touring
2001 Eurovan FOR SALE
1985 300D car, sold and missed.
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  #5  
Old 07-30-2014, 08:37 PM
cfh cfh is offline
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I'm trying to remove the stalk to get a new leather shift boot on from the bottom - because I can't figure out how to get the knob off to sip it on from the top. Anyone have any suggestions on the best way to get a new boot on? And what's this about a plastic top hat? Does it have anything to do with getting the stalk off? (Hope this is not too far off track from the OP's thread).
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  #6  
Old 07-31-2014, 12:08 AM
TheDon's Avatar
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I used an OEM top hat. Fun part is getting those washers in. I'll check that site out.

To swap shift boots peel it from the groove on the console and invert it. Loosen the lock nut to the shifter handle and then the shift knob threads off.

After reading one thread on rebuilding the w201 shifter I was correct in thinking that the trapezoid shim goes in last before the spring and rode go in. I'll have to try that tomorrow.
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|1982 300D Euro|OM617 NA| Thistle Green|"Granny Smith|
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  #7  
Old 07-31-2014, 11:04 PM
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I used a cut off pool Q to line up those pesky washers.
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  #8  
Old 08-06-2014, 07:37 PM
TheDon's Avatar
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Well I might need to use a dowel sanded to the exact
Profile of the washers because I tried it with a socket and extension and it didn't do much for me.

Assembling it and then sliding the plastic washer in worked
But then sliding the shifter home jostled everything out of place and I was back to square one.
I want to know how they assembled this thing at
The factory because this shouldn't be incredibly
Difficult.
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|1983 300D| OM617 239k Miles|Red|"Passion"|
|1982 300D Euro|OM617 NA| Thistle Green|"Granny Smith|
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  #9  
Old 08-06-2014, 08:26 PM
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Hopefully someone with some recent experience will chime in, about all I remember is the frustration
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1985 Euro 300TD 5 spd 220K
1985 Euro 240D 5 spd 130K
1979 240D 5 spd, 40K on engine rebuild
1994 Dodge/Cummins, 5 spd, 121K
1964 Allice Chalmers D15 tractor
2014 Kubota L3800 tractor
1964 VW bug

"Lifes too short to drive a boring car"
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  #10  
Old 08-06-2014, 08:55 PM
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hmm is this up there, with accidentally removing the half moon shape clip from the bottom of the hood star
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